CX460 TIER 3 CRAWLER EXCAVATOR SERVICE MANUAL TABLE OF CONTENTS DIVISION/SECTION
SECTION N°
REFERENCE N°
1
GENERAL INFORMATION Safety, general information and standard torque data ..................................... 1001 General specifications and special torque setting ........................................... 1002
7-27691EN SC4601002-0EN
2
ENGINE Radiator and oil-cooler .................................................................................... 2001 Engine specifications ..............................................................................................* Disassembly and assembly of the engine ..............................................................*
3
FUEL SYSTEM Fuel tank .......................................................................................................... 3001 Fuel engine system ................................................................................................*
4
ELECTRICAL SYSTEM Electrical system, electrical and electronic troubleshooting ............................ 4001 Main and engine electronic control boxes ....................................................... 4003
SC4604001-0EN SM4604003-0EN
5
UNDERCARRIAGE Removal and installation of tracks ................................................................... 5001 Rollers .. .......................................................................................................... 5003 Sprocket........................................................................................................... 5004 Idler wheel and tension shock absorber .......................................................... 5005
SM160B5001-0EN SM4605003-0EN SM160B5004-0EN SM4605005-0EN
6
DRIVE TRAIN Drive motor and final drive transmission removal and installation ................... 6001 Swing reduction gear, removal and installation ............................................... 6003 Swing reduction gear, disassembly and assembly .......................................... 6004 Travel reduction gear disassembly and assembly .......................................... 6005
SM4606001-0EN SM4606003-0EN SM4606004-0EN SM4606005-0EN
7
UNDERCARRIAGE HYDRAULICS
8
UPPERSTRUCTURE HYDRAULICS Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components.............................................. 8000 Specifications, troubleshooting, checks and hydraulic pressure settings ........ 8001 Hydraulic reservoir removal and installation ................................................... 8002 Main and hydraulic pilot pumps, removal and installation .............................. 8003 Main hydraulic control valve, removal and installation .................................... 8004 Attachment cylinders, removal and installation ............................................... 8005 Hydraulic swivel, removal and installation ...................................................... 8006 Pilot blocs, removal and installation................................................................. 8007 Swing motor, removal and installation ............................................................. 8008 Main hydraulic pump, disassembly and assembly ........................................... 8010 Main hydraulic control valve, disassembly and assembly................................ 8011 Attachment cylinders, disassembly and assembly .......................................... 8012 Hand control levers, disassembly and assembly ............................................. 8013 Foot control levers, disassembly and assembly............................................... 8014 Six-solenoid valves, disassembly and assembly ............................................. 8015 Caution valve, disassembly and assembly ...................................................... 8016 Safety valves.................................................................................................... 8017 Hydraulic swivel, disassembly and assembly .................................................. 8018 Swing motor, disassembly and assembly ........................................................ 8019 Hydraulic functions .......................................................................................... 8020 Travel hydraulic motor, disassembly and assembly ......................................... 8021 Fan motor, removal and installation ................................................................. 8022 Fan motor, disassembly and assembly............................................................ 8023 Fan pump, removal, disassembly, assembly and installation........................... 8024 Hydraulic component functions........................................................................ 8030
SM4602001-0EN
SM4603001-0EN
SM4608000-0EN SC4608001-0EN SM4608002-0EN SM4608003-0EN SM4608004-0EN SM4608005-0EN SM4608006-0EN SM4608007-0EN SM4608008-0EN SM4608010-0EN SM4608011-0EN SM4608012-0EN SM4608013-0EN SM4608014-0EN SM4608015-0EN SM4608016-0EN SM4608017-0EN SM4608018-0EN SM4608019-0EN SC4608020-0EN SM4608021-0EN SM4608022-0EN SM4608023-0EN SM4608024-0EN SC4608030-0EN
DIVISION/SECTION 9
SECTION N°
UPPERSTRUCTURE Upperstructure, turntable and counterweight..................................................... 9002 Boom, dipper and bucket ................................................................................... 9003 Seat, removal and installation............................................................................ 9004 Cab and cab equipment..................................................................................... 9005 Air conditioning unit disassembly and assembly................................................ 9007 Large size hydraulic schematics ......................................................................Pocket Large size electrical schematics ......................................................................Pocket
REFERENCE N° SM4609002-0EN SM4609003-0EN SM4609004-0EN SM4609005-0EN SM4609007-0EN 87574463A 87574470A
* Consult the Engine Service Manual NOTE: CNH Company reserves the right to make changes in the specifica tion and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.
Lep SM460TOC-0EN
Issued 09-07
1001-2
TABLE OF CONTENTS GENERAL INFORMATION .......................................................................................................................................3 SAFETY..................................................................................................................................................................... 4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
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WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep 7-27691EN
Issued 02-06
1001-3
GENERAL INFORMATION Cleanning
Gears
Clean all metal par ts except bear ings, in a suitab le cleaning so lvent or b y ste am clea ning. Do not use caustic sod a f or st eam clean ing. After clea ning, dry and put o il on al l pa rts. Clea n o il p assages with compressed air. Clean bearings in a suitable cleaning solvent, dry th e be arings completely an d pu t oil on the bearings.
Check all gears for wear and damage. Replace gears that have wear or damage.
Inspection Check a ll parts whe n th e pa rts ar e disassemb led. Replace a ll pa rts t hat h ave wear o r d amage. Small scoring or g rooves can be r emoved wit h a ho ne o r crocus clot h. Com plete a visual in spection for indications of w ear, p itting an d the r eplacement o f parts necessary to prevent early failures.
Bearings Check b earings f or easy actio n. If be arings ha ve a loose f it or ro ugh act ion r eplace t he bea ring. W ash bearings wit h a suitable cle aning solvent a nd p ermit to air dr y. DO NO T DR Y BEARIN GS WITH COMPRESSED AIR.
Needle bearings Before y ou pr ess nee dle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.
Lep 7-27691EN
Oil seals, O-rings and gaskets Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings.
Shafts Check all shaf ts t hat ha ve w ear or dam age. Ch eck the bearing a nd oil seal surfaces of t he sha fts f or damage.
Service parts Always install gen uine Case ser vice par ts. When ordering refer to the Parts Catalog for the correct part number of t he g enuine Case r eplacement ite ms. Failures due to the use of other than ge nuine Ca se replacement parts are not covered by warranty.
Lubrication Only use t he o ils and lubr icants spe cified in t he Operator’s or Service Ma nuals. Failures du e to th e use o f no n-specified o ils an d lub ricants are not covered by warranty.
Issued 02-06
1001-4
SAFETY
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This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.
To prevent injur y always follow the Warning, Caution and Danger notes in t his section and throughout the manual. Put th e warning t ag sh own be low on th e key for t he keyswitch w hen ser vicing or repairing the machine . One warning t ag is supplied with ea ch m achine. Additional ta gs Part Numb er 331-4614 are available from your service parts supplier
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WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n machine operation, service and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from your Case dealer.
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WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing.
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WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution.
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WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure.
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WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way.
.
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WARNING: Read the operator’s manual to familiarize yourself with the correct control functions.
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WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.
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WARNING: This is a one man machine, no riders allowed.
Lep 7-27691EN
Issued 02-06
1001-5
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WARNING: When servicing or repairing the machine, keep the shop floor and operator’s compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times.
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WARNING: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual.
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WARNING: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area.
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WARNING: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.
WARNING: Use insulated gloves or mittens when working with hot parts.
WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. WARNING: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood.
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WARNING: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer.
!
WARNING: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors).
!
WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands.
Lep 7-27691EN
Issued 02-06
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cle aning solvent and dr ied. Apply 2- 3 d rops of Lo ctite t o t he th read p ortion o f th e cap screw an d t hen tighten.
Torque table Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) Spanner Cap Screw Tightening torque
Socket Head Cap Screw
Lep 7-27691EN
Spanner Tightening torque
M6 [mm]
M8
M10
M12
M14
M16
M18
M20
10
13
17
19
22
24
27
30
[in.]
0.39
0.51
0.67
0.75
0.87
0.95
1.06
1.18
[Nm]
6.9
19.6
39.2
58.8
98.1
156.9
196.1
294.2
[lb-ft]
5.1
14.5
28.9
43.4
72.3
115.7
144.6
217
[mm]
5
6
8
10
12
14
14
17
[in.]
0.20
0.24
0.32
0.39
0.47
0.55
0.55
0.67
[Nm]
8.8
21.6
42.1
78.5
117.7
176.5
245.2
343.2
[lb-ft]
6.5
15.9
31.1
57.9
86.9
130.2
181
253.2
Issued 02-06
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1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS
CNH
Lep SC4601002-0EN
1002
Section
1002-2
TABLE OF CONTENTS
!
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5 Machine ....................................................................................................................................................................... 5 Engine .......................................................................................................................................................................... 5 Serial numbers of the components .............................................................................................................................. 5 FLUIDS AND LUBRICANTS ............................................................................................................................................ 6 Hydraulic fluid .............................................................................................................................................................. 6 Transmission component oil ........................................................................................................................................ 6 Grease ......................................................................................................................................................................... 6 Engine Oil .................................................................................................................................................................... 7 Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8 Anti-freeze/Anti-corrosion........................................................................................................................................... 10 Environment ............................................................................................................................................................... 10 Plastic and resin parts................................................................................................................................................ 10 SPECIFICATIONS ......................................................................................................................................................... 11 Main data ................................................................................................................................................................... 11 Performance .............................................................................................................................................................. 11 Complete machine dimensions .................................................................................................................................. 11 Main body dimensions ............................................................................................................................................... 11 Engine ........................................................................................................................................................................ 12 Cooling system .......................................................................................................................................................... 12 Capacity of coolant and lubricants ............................................................................................................................. 12 Hydraulic oil filter........................................................................................................................................................ 12 Fuel filter .................................................................................................................................................................... 12 Operating devices ...................................................................................................................................................... 13 Hydraulic system........................................................................................................................................................ 14 Swing unit .................................................................................................................................................................. 16 Travel lower body....................................................................................................................................................... 16 Work Unit ................................................................................................................................................................... 17 Digging force (ISO 6015) ........................................................................................................................................... 18 COMPONENT WEIGHT................................................................................................................................................. 19 Major component weight ............................................................................................................................................ 19 Bucket weight............................................................................................................................................................. 20 Other component weight ............................................................................................................................................ 21 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 22 Sprocket ..................................................................................................................................................................... 22 Idler wheel.................................................................................................................................................................. 23 Lep SC4601002-0EN
Issued 03-07
1002-3 Upper roller .................................................................................................................................................................24 Lower roller .................................................................................................................................................................25 Track...........................................................................................................................................................................26 DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................27 1. Boom foot/Frame ....................................................................................................................................................27 2. Boom cylinder foot/Frame.......................................................................................................................................28 3. Boom cylinder head/Boom......................................................................................................................................28 4. Arm cylinder foot/Boom ..........................................................................................................................................29 5. Boom/Arm...............................................................................................................................................................29 6. Arm cylinder head/Arm ...........................................................................................................................................29 7. Bucket cylinder foot/Arm.........................................................................................................................................30 8. Connecting rod/Arm................................................................................................................................................30 9. Compensator/Bucket ..............................................................................................................................................30 10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................31 11. Arm/Bucket ...........................................................................................................................................................31 SHIMS FOR ADJUSTING ATTACHMENT GAPS ..........................................................................................................32 For boom foot .............................................................................................................................................................32 SPECIAL TORQUE SETTINGS......................................................................................................................................33 MACHINE OVERALL DIMENSIONS ..............................................................................................................................36
Lep SC4601002-0EN
Issued 03-07
1002-5
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE For all part orders, request for information or assistance, always specify the type and the serial number of the machine to your Case dealer. Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the serial numbers of the hydraulic and mechanical components.
Machine 1 2
3
CT04A171A
(1) Type ....................................................................................................................................................................... (2) Serial number ........................................................................................................................................................ (3) Year of manufacture...............................................................................................................................................
Engine Make and type............................................................................................................................................................. Serial number..............................................................................................................................................................
Serial numbers of the components Hydraulic pump ........................................................................................................................................................... Swing reduction gear .................................................................................................................................................. Travel reduction gears ................................................................................................................................................. Control valve ...............................................................................................................................................................
Lep SC4601002-0EN
Issued 03-07